flsmidth filtration for tailings management · the information contained or referenced in this...

The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.

FLSmidth Filtration for Tailings ManagementTodd Wisdom+1-801-230-8409


Wet Tailings Solutions

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The L-L embankment of the Valley impoundmentThe Highland Valley Copper Mine is located just outside the

town of Kamloops in British Columbia, Canada. The mine produces copper (435,000 tones in 2003) and molybdenum

(6405 tones in 2003) concentrates. The tailings pumped to the Valley Impoundment in 2003 were 48.5 million tons.

The L-L embankment of the Valley impoundmentThe Highland Valley Copper Mine is located just outside the

town of Kamloops in British Columbia, Canada. The mine produces copper (435,000 tones in 2003) and molybdenum

(6405 tones in 2003) concentrates. The tailings pumped to the Valley Impoundment in 2003 were 48.5 million tons.

Lisheen mine tailings pond (Vedanta) in IrelandLisheen mine tailings pond (Vedanta) in Ireland

River and sea disposal Submarine Tailings Disposal (STD)is perhaps the most common offshore disposal technique and

involves the deep water discharge of tailings to the sea

River and sea disposal Submarine Tailings Disposal (STD)is perhaps the most common offshore disposal technique and

involves the deep water discharge of tailings to the sea


• Depending on the type of mineral the tailings can represent anywhere from 30% to 99% of the solids mined

• Most minerals tailings currently are handled with wet tailings process and stored in tailings impoundments

• These need careful construction, maintenance and monitoring, and also suffer from high evaporation/loss rates

Facts about Tailings and the handling processes


• Depending on the type of mineral the tailings can represent anywhere from 30% to 99% of the solids mined

• Most minerals tailings currently are handled with wet tailings process and stored in tailings impoundments

• These need careful construction, maintenance and monitoring, and also suffer from high evaporation/loss rates

• Several drivers towards dry tailings, including:o lack and cost of water o Suitable tailing pond lands, o reclamation responsibilities, o environmental legislation and, o wet tailings storage risks



Dry Stacking Drivers

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Tailings Solutions Options

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Dry stacking-La Coipa Mine (Anglo American, Chile)Dry stacking-La Coipa Mine (Anglo American, Chile)

Surface thickened Thickened discharge at Kidd Creek, ON, Canada (left)

and at Mt Keith, Western Australia (right)

Surface thickened Thickened discharge at Kidd Creek, ON, Canada (left)

and at Mt Keith, Western Australia (right)

Surface paste disposal at Myra Falls Mine, Vancouver Island, Canada

Surface paste disposal at Myra Falls Mine, Vancouver Island, Canada

Fresh paste depositing over a desiccated layer (left) and one of the risers at the Bulyanhulu Mine (Barrick), Tanzania

(Courtesy Golder Associates)

Fresh paste depositing over a desiccated layer (left) and one of the risers at the Bulyanhulu Mine (Barrick), Tanzania

(Courtesy Golder Associates)


Wet or Dry Tailings?

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Water ratio’s for typical granular tailings

Slurry % solids H2O vol. / mt Tailings (m3/mt)

Description

20 4.0 Ore processing30 2.3 Plant tailings50 1.0 Thickened slurry60 0.67 High Density slurry75 0.33 Thickened to paste82 0.21 Vacuum filter88 0.13 Pressure filter

COURTESY MINE PASTE ENGINEERING LTD.


Slurry Material Continuum

COURTESY MINE PASTE ENGINEERING LTD.


• The dry tailings process will increase with new operations, especially those situated in deserts environments and areas where tailings land availability is a constraining factor

• Solids content in thickened tailings is between 40% and 70%.

• Dry cake tailings solutions can increase the solids content to as high as 85%, which represents substantial water savings for the mine

• Dry tailings are also easier to reclaim and have lower environmental impact risks during operation and after the closure

• Dry Tailings provide the lowest risk profile with respect to failures and the costs associated with cleaning up those failures.



Tailings accidents

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The TVA Kingston Fossil Plant coal in the USA fly ash slurry spill occurred just before 1 a.m. on Monday December 22, 2008, when an ash dike ruptured at an 84-acre (0.34 km2) solid waste containment area at the Tennessee Valley Authority's Kingston Fossil Plant in Roane County, Tennessee, USA. 1.1 billion gallons (4.2 million m³) of coal fly ash slurry was released.

The TVA Kingston Fossil Plant coal in the USA fly ash slurry spill occurred just before 1 a.m. on Monday December 22, 2008, when an ash dike ruptured at an 84-acre (0.34 km2) solid waste containment area at the Tennessee Valley Authority's Kingston Fossil Plant in Roane County, Tennessee, USA. 1.1 billion gallons (4.2 million m³) of coal fly ash slurry was released.

Accident in Stava Trento Italy, 1985Cycloned sand tailingsAlong its path, the mud killed 268 people and completely destroyed 3 hotels, 53 homes, and six industrial buildings; 8 bridges were demolished and 9 buildings were seriously damaged. A thick layer of mud measuring between 20 and 40 cm in thickness covered an overall 435,000 square m over 4.2 km. According to the subsequent inquiries, the collapse was caused by the chronic instability of the dams, especially in the upper one, which were below the minimum factor of safety required to avoid collapses.

Accident in Stava Trento Italy, 1985Cycloned sand tailingsAlong its path, the mud killed 268 people and completely destroyed 3 hotels, 53 homes, and six industrial buildings; 8 bridges were demolished and 9 buildings were seriously damaged. A thick layer of mud measuring between 20 and 40 cm in thickness covered an overall 435,000 square m over 4.2 km. According to the subsequent inquiries, the collapse was caused by the chronic instability of the dams, especially in the upper one, which were below the minimum factor of safety required to avoid collapses. Marriespruit South Africa 1994

Wet tailingsMarriespruit South Africa 1994

Wet tailings

Cerro Negro near Santiago Chile 2003Wet tailings

Cerro Negro near Santiago Chile 2003Wet tailings

The majority of historical tailings related incidents have been influenced by poor day to day management.


Tailings accidents

The Ajka Timfoldgyar Alumina Plant Tailings Dam Accident October 4th 2010 in Hungary. Hungary's government estimated that it would cost more than US$51 million and take at least a year to clean up the

damage. Hungarian state news service MTI estimated at the time of the accident that Hungary stores about 50 million tons of the red tailings with about 800,000 tons generated annually.

The Ajka Timfoldgyar Alumina Plant Tailings Dam Accident October 4th 2010 in Hungary. Hungary's government estimated that it would cost more than US$51 million and take at least a year to clean up the

damage. Hungarian state news service MTI estimated at the time of the accident that Hungary stores about 50 million tons of the red tailings with about 800,000 tons generated annually.

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World Market for Dry TailingsExpected high global growth

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Dry Tailings Global Market Outlook

& FLSmidth Strategy

Dry Tailings Global Market Outlook

& FLSmidth Strategy

Dry Tailings Opportunities

& FLSmidth Locations

Dry Tailings Opportunities

& FLSmidth Locations

Dry Tailings

Dry, desert areas, lack of water. Southern Hemisphere in specific

Water issues and TSF type guided by strong environmental legislation

Very cold climates, freezing temperatures, permafrost

Dry Tailings

Dry, desert areas, lack of water. Southern Hemisphere in specific

Water issues and TSF type guided by strong environmental legislation

Very cold climates, freezing temperatures, permafrost

FLSmidth’s Tailings Strategy

2011 One of the leading suppliers of tailings

equipment and bundled products. Near Future The leading supplier of dry tailings islands

solutions. Long Term The Leading supplier of dry tailings

management solutions

FLSmidth’s Tailings Strategy

2011 One of the leading suppliers of tailings

equipment and bundled products. Near Future The leading supplier of dry tailings islands

solutions. Long Term The Leading supplier of dry tailings

management solutions

Very Warm,Very Dry

Very Cold

Targeted markets#1 Copper, Gold, Coal#2 All base metals and PMs


FLS Dry Tailings Solutions

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FLS Values for Tailings Solutions

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FLSmidth FiltrationKey filter lines

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Vacuum FiltersVacuum Filters

Horizontal Belt Filters and Pan Filters up to 250m2

High Performance and Flexible Vertical

Drum Filters and Disc Filters up to 310m2

Simple, Robust and Reliable

Horizontal Belt Filters and Pan Filters up to 250m2

High Performance and Flexible Vertical

Drum Filters and Disc Filters up to 310m2

Simple, Robust and Reliable

Pressure FiltersPressure Filters

Horizontal Filter Press up to 24m2 volume, 960m2 area Simple, Robust and Reliable

Vertical Pheumapress up to 100m2 area High Performance and Flexible

Horizontal Filter Press up to 24m2 volume, 960m2 area Simple, Robust and Reliable

Vertical Pheumapress up to 100m2 area High Performance and Flexible

Global ClientsGlobal Clients


Lab and Pilot Testing

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Bench-Scale and/or Pilot Testing are used todetermine material filtration characteristics For equipment proper selection and sizing.

Bench-Scale and/or Pilot Testing are used todetermine material filtration characteristics For equipment proper selection and sizing.


AFP Pilot Unit

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FLSmidth Pilot Filter Press 500mm Membrane Mixed-Pack Plate Stack

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Tailings Dewatering Options Tested

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Options for Tailings Dewatering

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Total Tails 18 % CakeP80 – 204

Total Tails 18 % CakeP80 – 204

Fine Tails – Cyclone Overflow26% Cake P80 - 30.5

Fine Tails – Cyclone Overflow26% Cake P80 - 30.5


Most Effective Solution – Filter Cake

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Filter Press Technology Produce Consistent Dry Cake w/o the Need for Expensive Polymers

Filter Press Technology Produce Consistent Dry Cake w/o the Need for Expensive Polymers

Refuse BeltRefuse BeltCoal Refuse Filter CakeCoal Refuse Filter Cake


Full Range of Filter Press Products

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Low Cost Standard Products

Low Cost Standard Products

Filter Presses from small to large / Fully and Fully Automatic to Fully Manual

Filter Presses from small to large / Fully and Fully Automatic to Fully Manual

High Performance

Advanced Products

High Performance

Advanced Products

Worlds Largest Minerals Filter Press 10% capital cost saving

120 Chambers – twice the size of Competitors

2x2 lower feed eye filter plates

Worlds Largest Minerals Filter Press 10% capital cost saving

120 Chambers – twice the size of Competitors

2x2 lower feed eye filter plates


• TCO must be competitive with traditional solutions• High Initial Costs > $100,000,000 USD• Low Operating Costs > $0.75 USD/ton

• Minimize Filtration Capital Costs• Minimize Cycle time• Maximum Filter Size

• Minimize Filtration Operational Costs• Minimize energy usage• Eliminate wasted energy• Minimize Cloth Consumption• Use cost effective design

Key Elements for Cost Effective Filter Design


For High-Volume ProductionLarge-Scale Filters with 2M x 2M Plates

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Filter Specifications: 2 x 2 Plates 16 bar rated Overhead Type 100 Bar Cloth Washer

Filter Specifications: 2 x 2 Plates 16 bar rated Overhead Type 100 Bar Cloth Washer


Single Plate Indexing – Discharge =10 min.

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Shriver® Filter PressShriver® Filter Press


Cake Filtration STAGES ‐ DewateringA

ir flo

w ra

te m

3/M

IN


Typical Tailings Cycle Time


Top Feed MembraneTop Feed Membrane

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Bottom Feed Recessed ChamberBottom Feed Recessed Chamber

Minimize Cycle Time Eliminate Membranes


AFP IVTM FILTERFiltration Pressure

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Slurry Pumps Are Used To Create The Filtration Flow and Pressure

VFD control ensures pumps operate to required filtration curve.

Slurry Pumps Are Used To Create The Filtration Flow and Pressure

VFD control ensures pumps operate to required filtration curve.

Uniform Filling

Uniform Filling

Cake Forms in Layers

Cake Forms in Layers

Homogenous Cake

Homogenous Cake

Liquid Core Allows Pressure to be Applied Uniformly Over

Entire Forming Cake

Liquid Core Allows Pressure to be Applied Uniformly Over

Entire Forming CakeTurbulence MaintainedTurbulence Maintained


CompetitionUpper Feed Eye

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Chambers fill in series, not in parallel

Cakes are more consolidated at the bottom of the plate than at the top of the plate

Membranes are required to consolidate into even cakes

Chambers fill in series, not in parallel

Cakes are more consolidated at the bottom of the plate than at the top of the plate

Membranes are required to consolidate into even cakes

Low densityLow density

High densityHigh density


PLATE DESIGN

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Membrane Plate SectionMembrane Plate Section


Filter Plates Comparison

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Membranes required Plate removal not required for

cloth change Plate life limited Cost up to US$ 20,000 each Membrane accessories needed –

higher Opex Longer cycles for membrane

squeeze means less production per cycle and more filter press area required

Membranes required Plate removal not required for

cloth change Plate life limited Cost up to US$ 20,000 each Membrane accessories needed –

higher Opex Longer cycles for membrane

squeeze means less production per cycle and more filter press area required

No membranes required Remove plate for cloth change –

Not significant Plate life extended Cost US$2,000 each

No membranes required Remove plate for cloth change –

Not significant Plate life extended Cost US$2,000 each

Top FeedTop Feed Bottom Feed – FLS TechnologyBottom Feed – FLS Technology


Minimize Cycle Time Discharges In < 1 Min.

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AFP IV™ Automatic Filter Press AFP IV™ Automatic Filter Press


Cross Head System Discharges 120 Chambers in < 1 Min.

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Cross head system lock pinsCross head system lock pins


Optimized Design

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Rolling Crosshead and Follower

Rolling Crosshead and Follower

ShakerShaker

Flood Wash SystemFlood Wash SystemFilter Plate SystemFilter Plate System


The Heart of Filtered TailingsAFP IV™ Automatic Filter Press

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Filter and Drip Tray on Assembly FloorFilter and Drip Tray on Assembly Floor


AFP IV™ Automatic Filter Press

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Automatic Filter PressAFP Operation (without Cake Wash)

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Automatic Filter PressCore Blowing to Clear Feed Eye

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For High-Volume ProductionLarge-Scale Filters with 2M x 2M Plates

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Filter Specifications: 9,015 ft2 (838 M2) 475 ft3 (13.5 M3) 225 psi (16 bar) Dry Wgt: 165 tons

Filter Specifications: 9,015 ft2 (838 M2) 475 ft3 (13.5 M3) 225 psi (16 bar) Dry Wgt: 165 tons


Typical Open Discharge Arrangement

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Filtrate is Discharged

Directly to the Drip Tray or

Launder

Filtrate is Discharged

Directly to the Drip Tray or

Launder


Flood Wash Arrangement

Water ConnectionWater ConnectionBottom Wash SupplyBottom Wash Supply


Shaker System

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Right Angle Gearbox

Right Angle Gearbox

Right Angle Gearbox

Right Angle Gearbox

Gear BoxGear Box

Hydraulic MotorHydraulic Motor

Shaker Drive ConfigurationShaker Drive Configuration


FLSmidth Automation Controlsw/Local PLC and DCS Connectivity

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Largest Operating Minerals Filter Press (14) (12 operating 2 spare) 2x2 AFP Filters 120 Chambers Capable of 100,000 mt per day

8,300 tpd/filter 65 % feed solids 16 % cake moisture

Largest Operating Minerals Filter Press (14) (12 operating 2 spare) 2x2 AFP Filters 120 Chambers Capable of 100,000 mt per day

8,300 tpd/filter 65 % feed solids 16 % cake moisture

Copper Tailings Filtration


Rosemont Copper Tailings FiltrationTotal Tailings Dewatering


Filter Press with Surge Tank

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Normally Used with Conventional Thickener Technology


Rosemont

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Rosemont Tailings

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FILTRATION CYCLE TIMES(Minutes)

Fill Empty Filter 0.57Filtration to Solids Consolidation 3.07Wash Solids 0.00Cake Blow 4.00Core Wash/Blow 0.50Shake Cloth 0.50Filter Cloth Wash & Purge 0.50Open & Close Filter 1.50

Total Cycle Time 10.64

FILTRATION CYCLE TIMES(Minutes)

Fill Empty Filter 0.57Filtration to Solids Consolidation 3.07Wash Solids 0.00Cake Blow 4.00Core Wash/Blow 0.50Shake Cloth 0.50Filter Cloth Wash & Purge 0.50Open & Close Filter 1.50

Total Cycle Time 10.64

0.0%

2.0%

4.0%

6.0%

8.0%

10.0%

12.0%

14.0%

16.0%

18.0%

20.0%

0 1 2 3 4 5 6 7 8W

eigh

t % C

ake

Moi

stur

eTime, Minutes

Cake Moisture vs. Time

S…

P80 127 micronsP80 127 microns

~ 8,500 tpd / filter~ 350 tph / filter~ 16 wt% cake moisture


M2020 in Operation

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Copper Tailings Filtration Scenarios(Data From Testing)

Type Combined Fine and Coarse Fine

Solid Sg 2.73 2.73

Feed Wt% Solids 50 50

P80µm 204 30.5

Mtph 10570 5913

Cake Moisture Wt % 18.5 25.9

Cake Thickness mm 32 32

Filter Type Recessed Chamber Recessed Chamber

Total Cycle Time (min) 9.4 10.63

Filtration Rate kgh/m2 (lb/h/ft2) 183 (38) 146 (30)

Terminal Feed Pressure kg/cm2

(psi)9 (140) 9 (140)

Filter Size (ea) M2020 – Ch Qty/M2/M3

152/1018/19 152/1018/19

Qty Filter Required 57 40


M1500 – 77 Chambers Copper Concentrate Slurry Sg: 1.86 Cake Dryness: 8-9 wt% Through put: 1200 mtpd Availability: >90% Cycles Operated: >100,000

M1500 – 77 Chambers Copper Concentrate Slurry Sg: 1.86 Cake Dryness: 8-9 wt% Through put: 1200 mtpd Availability: >90% Cycles Operated: >100,000

Filter Press

Mongolian Copper MineMongolian Copper Mine


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FLSmidth Automatic Filter Installation



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Operating Costs


Patent Pending Colossal AFP

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Copper Tailings FiltrationWorlds Largest Filter Press Twice the capacity of current filters 120 Chambers Each filter > 15,000 tpd/filter

Worlds Largest Filter Press Twice the capacity of current filters 120 Chambers Each filter > 15,000 tpd/filter


FLS Dewatering Plant

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FLSmidth Plant LayoutFourteen (14) Automatic Pressure Filters Total Filter Area 12,000 Sq M

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FLS Plant Layout w/14 Pressure FiltersFilter Cake Collection System

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Summary

Largest Filter on the Market

Lower Feed Eye = High Equipment Availability

Heavy-duty = Less Down Time

No diaphragms = Less maintenance

Inexpensive filter plates

Short Cycles = High Throughput Per Area

Reduced number of filters

Low installed cost

Low Cost sourcing available

Largest Filter on the Market

Lower Feed Eye = High Equipment Availability

Heavy-duty = Less Down Time

No diaphragms = Less maintenance

Inexpensive filter plates

Short Cycles = High Throughput Per Area

Reduced number of filters

Low installed cost

Low Cost sourcing available

FLS Filter Press Advantages:FLS Filter Press Advantages:


Summary

Maximum Water Recovery

Minimum Fresh Water Needed

Lowest Environmental Impact

Co-current Land Reclimation

Lowest Risk Profile

Competitive Life Cycle Costs

Maximum Water Recovery

Minimum Fresh Water Needed

Lowest Environmental Impact

Co-current Land Reclimation

Lowest Risk Profile

Competitive Life Cycle Costs

Filtered Tailings Advantages:Filtered Tailings Advantages:


FLSmidth Conveyor-Based Dry Tailings StackingTed WagnerGlobal Product Manager – Mobile Conveying

flsmidth filtration for tailings management · the information contained or referenced in this...

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